Preparation of Al–Fe–V–Si alloy by spray co-deposition with added its over-sprayed powders

In this paper, a new method to prepare Al–8.5Fe–1.3V–1.7Si (FVS0812) alloy by spray co-deposition with added its over-sprayed powders was studied. Two kinds of powders which are different in particle size (≤43, 43–74 μm) were used in the new process. Under the same experimental conditions, the alloys were produced by spray deposition without powders and the spray co-deposition. The deposited alloys were subsequently hot extruded with an extrusion ratio of 16:1 at 450 °C. The results showed that the addition of over-sprayed powders refined the microstructure and improved the mechanical properties, and the effect of the fine over-sprayed powders was more evident than that of the coarse powders. The ultimate tensile strength was enhanced from 360.5 MPa (without powders) to 433.3 MPa (≤43 μm) and 392.4 MPa (43–74 μm). The mechanical properties increase is mainly due to the over-sprayed powders pulverizing melt effectively, absorbing heat greatly and increasing the number of heterogeneous nuclei in matrix, which result in the enhancement of cooling rate and the refinement of microstructure.